Building Work Packages - Construction Owners Association of Alberta

Building Work Packages

Session Format• Introduction• Overview of the COAA approach to buildingWork Packages• The Graham approach to building work packages• The JV Driver approach to building work packages• The Ledcor approach to building work packages• Audience participation• Questions to panel

What is in an FIWP?

The COAA Approach toBuilding Work PackagesField Installation Work Packages (FIWP)

The COAA Approach toBuilding Work Packages• Who develops the FIWP?• FIWPs are developed by dedicated planners (craftspeople or engineering types with constructionexperience).• Note: In some cases General Foremen orsuperintendents may develop the FIWP

• How big is an FIWP?The COAA Approach toBuilding Work Packageso Normally 500 to 1000hours (but varies basedon discipline and workbeing done)

The COAA Approach toBuilding Work Packages• Can you use an FIWP thatdoesn`t have satisfiedconstraints?oNot normally, but youcan modify the packageto ensure that the newpackage has satisfiedconstraints

The COAA Approach toBuilding Work Packages• What are FIWP built from?o Typically FIWPs aredeveloped fromConstruction WorkPackages but we areseeing FIWP developeddirectly from EngineeringWork packages

Traditional execution:The Graham Approach toBuilding Work Packages

The Graham Approach toBuilding Work Packages• Information• Materials• Tools• Equipment• Resources• Access to the WorkfaceScopeDrawingsPlanned ValueSchedule DatesMaterial ConfirmationConstruction EquipmentScaffold RequirementsSafetyQuality ControlLabourPermitRequirements

The Graham Approach toBuilding Work PackagesWorkface Planning Applied to Earthmoving

The Graham Approach toBuilding Work PackagesWorkface Planning Applied to Earthmoving• Standard set of FIWPs• FIWPs applied to a Lift (not to aforeman)• Foremen build daily plans tosatisfy the FIWP• Foremen report barriers daily

Beyond the COAA Model:The Graham Approach toBuilding Work Packages•WorkFace Planners develop execution plans with theirsuperintendents for each EWP•EP guides development of FIWPs•Standard earthmoving FIWPs (procedures)•Earthmoving FIWPs assigned to the task not the crew.•Foremen create daily plans•Barriers are logged and managed daily•Subcontract FIWPs: built by our planners with guidance fromtheir supervision

Wedding Scenario:The JV Driver Approach toBuilding Work Packages

The JV Driver Approach toBuilding Work Packages

FIWP Stakeholders Planners are in the Field Extract components tobuild the FIWPo HS&Eo Qualityo Project Controlso Scheduleo MaterialManagemento Document ControlThe JV Driver Approach toBuilding Work Packages

FIWP Stakeholders Planners are in the Field Extract components tobuild the FIWPo HS&Eo Qualityo Project Controlso Scheduleo MaterialManagemento Document ControlThe JV Driver Approach toBuilding Work Packages

• TCCC (Turnover, Care, Custody and Control)•The JV Driver Approach toFIWPs are returned Certified CompleteBuilding Work Packageso Red Line Drawingso As Built Drawingso Construction Punch Listo Signed and Completed ITPso Confirmation of Construction Completeo Precommissioning

The Ledcor Approach toBuilding Work PackagesBuilding Foreman’s Workface Packages

Question-and-Answer Period

AUDIENCE FEEDBACKNOTE: The information collected isanonymous and may be used forresearch purposes. By participating,you are giving your consent for theuse of this data.

Closing Comments• Thanks for attending this session and providingus with your feedback• If you have any further questions for any of thespeakers please ask us after the session

Building Foreman’sWorkface PackagesWFP Conference 2010Calgary, AlbertaDecember 1, 2010

Introduction to FIWP Planning“Plan the Work”“Release the Work”“Work the Plan”Dedicated PlannerSupervisorMaterials & EquipmentCoordinatorsPrerequisitesField Installation WorkPackageMaterialsToolsEquipmentTrades/SpecialistsDetailed PlanDrawingsVendor Info.Safety RequirementsSupervisor ReviewSafety and QAReady√Team37%Tools47%ScopeTool Time Improvement

GOALThe goal of Workface Planning is to improve performance by:• Develop a usable and practical standard planning tool to significantlyincrease productivity, reduce rework and enhance the probability ofproject success• Create and maintain discipline and foster honest communication toproactively resolve issues before and as they arise• The FIWP process will be a continuously improving body of knowledge• Based on the COAA Best Practices

PLAN THE WORKA Field Installation Work Packageis a comprehensive package ofInformation that describes aspecific scope of work in detail andtypically includes:•Safety & Quality considerations•Discipline Drawings•Material requirements•Inspection & Test Certification•Estimated number of man-hours•Schedule•Additional information…(To benefit the construction/implementation team.)

CWP Demarcation / IdentificationCWPCWPCWPCWPCWPCWPCWPCWPCWP27A25E27B25B25F25A25H26ACWPCWPCWPCWPCWPCWP25D25G26BDesign Area25A25B25C25D25E25F25G25H25JDesign Area Ref’s48A25CKey Plan Diagram25K26CUndergrounds• Design Area(s) are broken into a series of Construction Work Pkgs s (CWP)• CWPs are agreed to with Engineering prior to construction

Packaging Work for FIWP’s2 nd Step 1 st Step (Typically determined by area)3 rd StepAreasmappingLevel 3 - DisciplinesCWPCWPCWPFIWP’sLevel 4Estimate&ManhoursLevel 5FIWP Step ListingTaskTaskTaskTaskTaskTask

Foreman’s s Workface PackagePreparation Guiding Principles• Keep it SIMPLE• Practical and User Friendly• Understandable• Standardize Tools• Continuous Improvement

Packaging Work for FIWP’s s (cont’)4 th Step Create FIWPFIWP Document Template1. Introduction2. Health Safety & Environmental3. Scope Of Work4. Drawings & Data5. Material Data6. Inspection & Test Plan (QA/QC)7. Operation & Maintenance8. Support Information Dedicated AND Experienced planners break out CWP’s s into specificField Installation Work Packages (FIWP’s) The consideration for FIWP Packages is commended during thedetailed engineering phase

General overview of the scopeof work to be undertaken withspecific attention to any itemsneeding consideration byConstruction implementation.1.0 Introduction

2.0 Health Safety & Environmental• Hazard Management Activities• Work Pack Risk Assessment• Material Safety Data Sheets• Task Risk Assessment• Manual Handling• Specialist Safety Requirements• Provision & Use of Work Equip.• Toolbox Talks

3.0 Scope of Work• Piping• Mechanical• Instruments• Electrical• Civil/Structural• HVAC• Job Cards / Activity Sheets• Joint Completion Matrix• Lifting Requirements• Engineering Queries• Hydro/ Integrity Testing• Planning

4.0 Drawings & Data• Piping• Mechanical• Instruments• Electrical• Civil/ Structural• HVAC• Architectural• Lifting Requirements

5.0 MaterialsMaterial Requisitions• Piping• Mechanical• Instruments• Electrical• Civil/Structural• HVAC

FIWP - SmartPlant Materials IntegrationForecasts are created by Field Installation Work Package (FIWP) priority Only Inventory – Identify lines with 100% material on hand Approved Purchase Orders – Create shortage reportsShortage reports forwarded to expediting group Identify possible long lead items impacting schedule Focus expediting efforts where most neededMaterial list added to FIWP package and signed offPick tickets for 100% on hand inventory packages forwarded to thewarehouse for bag & tag and staging Release Authorization from warehouse Picked heat numbers recorded for later user by Quality AssuranceDepartment

Buildable List by FIWPReported by FIWP Package at Isometric LevelList of all Lines that are available to begin construction

6.0 Inspection & Test Certification• Owner Specification/ CodeInspection & Test requirements• Mechanical Completion Certification• Punch lists• Joint Integrity Certificate• Integrity Test Certificate• Control Completion Certificate(process control items)• System Handover Certificate

7.0 Operation & Maintenance• Operating Manual Updates• Maintenance Routine Updates

8.0 Additional Information• Procedures/ Work Instructions• Specifications• Miscellaneous Data• Weight Control• Vendor Data• Other Data

FIWP – Release The WorkEngineeringConstructionPlanningFIWP’sConstructionExecutionHandoverGenerate CWPDevelop executionMethods & scope(trade mix)FIWP Issuedfor ConstructionSub-SystemSystemCompletionrecordsEngineeringDeliverableListingHAZCON requirementsMethod StatementsRisk assessmentsResource/ PlanningI & T CertificationHyperlinkHyperlinkLedcor’s s Project Controls SystemsResponsible parties, which are to always include the Foreman, review the completeness andaccuracy of the FIWP package prior to commencing work in the fieldSuperintendents/PMs/Coordinators make final go/no-go decisions on FIWP releaseForemen execute FIWP’sProject Controls monitor FIWP’sQuality Assurance audit FIWP’s

SUMMARYThe Ledcor Group…Workface Planning to improveperformance by:Planning using Practical methodsMaking the “Bar” clearCreating disciplineProactively resolving issuesSignificantly increasing productivityReducing reworkContinuously Improving

OPEN PANEL DISCUSSIONFIWP Steel

How Big is an FIWP Package?Use Common Sense: It is a package of work as would normally be givento a foreman to build.• Work for an FIWP is to be discipline specific and to a individualForeman’s crew.• The size of an FIWP can depend on the complexity of the work.Therefore work may be of longer (or shorter) than 2-3 weeks in duration.(example - Large concrete foundation (4 weeks), setting a piece ofequipment (4 days).)• FIWP packaging needs to align with all systems. (i.e. Estimating, FWP,Schedule)• An FIWP may remain ‘open’ for longer periods (on hold at

Clarifier Base – Concrete Pour

OIL SANDS PROJECTHeavy lift of rotary crusher at C&C siloFirst pipe module being set at U&O silo

Oilsands SAGD ExpansionSetting OTSG Stack

DIAMOND MINE – Structural Steel

Central Processing Plant – PIPERACK MODULES

HEAT TRACING

Progress Monitoring and Control of FIWPs

Field Installation Work Package(FIWP) Planning InterfacesMC2EstimateSmart Plant 3DDesignP6ScheduleFWPProgressFIWPPackageQA / QCNDEWelder LogFWPPlanToolHoundTools & EquipmentSmartPlantMaterials

Foreman’s s Workplace• Foreman’s s Planning Tool• Compile Earned Progress• Report Earned Progress by− Foreman− Schedule ID− JDE Cost Code− System− CWP− FIWP• Data from IFC estimateinformation• Worksheets continually updatedto reflect current scope of work

FWP – Levels of DetailPIPEAreaCWP / EWPFIWPCONCRETELineISODesign AreaSpoolCWP / EWPFIWPInstallation ProgressFoundation

Concrete:Scorecard ComponentsPiping:• Itemized scope of work• Schedule IDs• Estimate MHs• Area/System/EWP/Line#/Iso#/Priority/etc…• Activity steps

FWP Main Screen• Sort and filter immediately by any column• Edit information directly on screen• Progress activities by percentage complete• Progress by standard sets of activities in a step-byby-step manner

Construction to ProductionFWP Seamless Transition…• Typically do notreceive completedetailed systemdefinition until 75%completeFWP ADVANTAGE• Can switch between Standardand System Sorts on the fly• Need systemdefinition as earlyas possible• FWP allowssystem informationto be enteredprogressively asinformationbecomes available• Greatly enhancesability to plan andexecute finalsystem by systemturnover

Construction to Production• Change the way we approachscheduling execution.• Use existing Ledcor systems to tie inEWP’s, FIWP’s s and turnover packagesto achieve optimum balance betweenconstruction and start up.• At the early onset of the project, focussuperintendents on the sequence of startup, not mechanical completion.• Continuous cross discipline interactiveplanning from EWP release throughconstruction to start up.